Specific embodiment
In order to make the object, technical scheme and advantages of the embodiment of the invention clearer, below in conjunction with the embodiment of the present inventionIn attached drawing, technical solution in the embodiment of the present invention is explicitly described, it is clear that described embodiment is the present inventionA part of the embodiment, instead of all the embodiments.Based on the embodiments of the present invention, those of ordinary skill in the art are not havingEvery other embodiment obtained under the premise of creative work is made, shall fall within the protection scope of the present invention.
Fig. 1 is a kind of driving mechanism trouble-shooter structural schematic diagram provided in an embodiment of the present invention, as shown in Figure 1,Including：
Acquisition module 1 and diagnostic module 2；
Wherein, the acquisition module 1 is connect with the PLC of the driving mechanism and the diagnostic module 2 respectively, described to adoptCollection module 1 is used to acquire the correlation signal of the driving mechanism, and the correlation signal of the driving mechanism is sent to described examineDisconnected module 2, the correlation signal includes several echo signals to be detected；
The diagnostic module 2 is used to detect the correlation signal of the driving mechanism, if any echo signal to be detectedIt is unsatisfactory for preset function logical table parameter value, then is diagnosed to be the corresponding fault type of corresponding function logical table.
It should be noted that driving mechanism trouble-shooter provided in an embodiment of the present invention is mainly used in EMU driveMotivation structure, but driving malfunction diagnosis dress provided in an embodiment of the present invention can also be used in the driving mechanism of some other mechanical equipmentIt sets, the present invention is not especially limit this.
Specifically, the embodiment of the present invention in order to realize automation to driving mechanism carry out fault diagnosis, mainly provideCollaboration is handled two modules jointly, wherein and the correlation signal that acquisition module 1 is responsible for that driving mechanism can be generated is acquired,It is understood that driving mechanism can generate all types of signals in use, such as：Power supply signal, PLC are inputted, are defeatedSignal out, motor input signal and position signal etc., the signal of each type can be used as the to be checked of the embodiment of the present inventionEcho signal is surveyed, can be configured according to actual needs.After acquisition module 1 completes the acquisition of driving mechanism correlation signal, meetingVarious correlation signals are all sent to diagnostic module 2.
It is understood that different types of signal is respectively provided with respective characteristics of signals, in order to diagnose mouldBlock 2 can be managed collectively and correctly diagnose, and the embodiment of the present invention preferably can convert binary form for all correlation signalsThe digital signal shown, i.e. " 01 " digital quantity signal.Correspondingly, 2 embodiment of the present invention of diagnostic module preferably selects single-chip microcontroller plate,Such as：Battleship STM32F103 plate diagnoses each correlation signal by the diagnostic program prepared in advance in single-chip microcontroller plate.
It is understood that being deposited between the correlation signal certainty and normal signal of acquisition when driving mechanism breaks downIn difference, then by being compared between real-time collected correlation signal and normal signal, can positioning failure occurType and abort situation.
For above-mentioned normal signal, the embodiment of the present invention has preset a function logic table to be differentiated, it is possible to understand that, function logic table be by driving mechanism normal operation in the case where multi collect summation determine, function logic tableIn parameter value it is identical with the representation of the correlation signal value of acquisition, can be by comparing so that it is determined that corresponding failure classesType.
Such as：When the signal parameter value of master control power supply in function logic table is 0, and master control in the correlation signal of real-time measurementThe signal of power supply is 1, then being then diagnosed to be master control power failure.The similar diagnosis situation embodiment of the present invention is herein no longerIt repeats.
It should be noted that driving mechanism trouble-shooter provided in an embodiment of the present invention is additionally provided with data storage mouldBlock, display module and WiFi module (not shown), it is to be understood that the diagnosis process of driving mechanism is one long-termSignal acquisition and analytic process, then preservation for data and backup are most important, for this situation, the embodiment of the present inventionThe data memory module preferably provided stores come the signal acquired to acquisition module 1, and data memory module canTo select the conventional memory devices such as SD card.So, worked as by the data that data memory module stores and need to carry out historical record inquiryWhen, can data be read from data memory module accordingly.
Further, in order to give the more intuitive information of operator, the embodiment of the present invention further preferably in driving mechanism thereforeIt is provided with display module in barrier diagnostic device, can in real time be shown the diagnostic message of driving mechanism by display module,Display module can select the display screen of 800*400 resolution ratio or more, and using capacitance touch screen, maximum can support at 5 points while touchIt touches, manipulation effect is splendid.And the included driving of the display screen, highest brush screen speed is up to 86 frames/second.Support 8/9/12/16The connection of 8080 parallel ports, it is easy to connect.
It should be noted that when in trouble hunting, it is sometimes desirable to by real-time data transmission to the end PC, realize data pointAnalysis.For this situation, the embodiment of the invention provides a WiFi modules to realize the demand, and user can be in WiFi moduleThe username and password for inputting scene WIFI, can be realized connection." starting to transmit " button being arranged in WiFi module is clicked, i.e.,It can be by real-time Data Transmission to the end PC.When no longer needing to transmit data, " the terminating transmission " being arranged in WiFi module is clicked i.e.It can stop transmitting data.
A kind of driving mechanism trouble-shooter provided in an embodiment of the present invention, passes through the association of automatic measurement driving mechanismSignal, and automatically match correlation signal in preset function logical table, so that whether diagnosis driving mechanism has occurred event automaticallyBarrier, reduces the labor intensity of technical staff and improves diagnosis efficiency.
On the basis of the above embodiments, Fig. 2 is another driving mechanism fault diagnosis dress provided in an embodiment of the present inventionStructural schematic diagram is set, the driving mechanism trouble-shooter further includes：
Power module 3, the power module 3 include voltage regulation unit 31 and circuit protection unit 32；
It is provided with switching regulator and low-pressure linear voltage-stablizer in the voltage regulation unit 31, for steady to the power modulePressure；
It is provided with protective tube and varistor in the circuit protection unit 32, for the driving mechanism fault diagnosisDevice carries out circuit protection.
As shown in Fig. 2, driving mechanism trouble-shooter provided in an embodiment of the present invention is additionally provided with a power module3, wherein voltage regulation unit 31 and circuit protection unit 32 are provided in power module 3.Since diagnostic module 2 (single-chip microcontroller plate) is usedPower supply majority is 24V voltage, and this overtension can bring unnecessary security risk, and in response to this problem, Fig. 3 is of the invention realThe voltage regulation unit circuit diagram of example offer is applied, power module 3 provided in an embodiment of the present invention can be right by voltage regulation unit 31Former power supply is depressured.Such as：The voltage of former 24V is reduced to 3.3V or 5V or 12V.
And in order to obtain higher security performance, circuit is additionally provided in power module 3 provided in an embodiment of the present inventionProtection location 32 is provided with protective tube and varistor in circuit protection unit 32, it is preferred that it is anti-that protective tube uses diodeThe mode connect has carried out circuit protection, then when voltage is higher, first can breakdown diode so that shorted diode, thusIt plays a protective role to diagnostic module 2.
On the basis of the above embodiments, Fig. 4 is another driving mechanism fault diagnosis dress provided in an embodiment of the present inventionStructural schematic diagram is set, as shown in figure 4, the driving mechanism trouble-shooter further includes：
Signal replacement module 4, the signal replacement module 4 respectively with the PLC of the driving mechanism and the diagnostic module 2Connection；
The signal replacement module 4 is for generating correct signal, to replace fault-signal.
By the content of above-described embodiment it is found that driving mechanism trouble-shooter provided in an embodiment of the present invention can pass throughThe correlation signal of driving mechanism is acquired to diagnose whether driving mechanism has occurred failure.So have really when driving mechanism is diagnosed to beWhen failure occurs, the embodiment of the present invention provides a signal replacement module 4 accordingly to repair to failure.
Signal replacement module 4 is able to use correct signal replacement driving mechanism fault-signal, allows driving mechanism justOften work.Specifically, signal replacement module 4 is cut off driving mechanism original signal using switch, and by correct signalInputing to driving mechanism replacement fault-signal makes its normal work.
Such as：If the output signal failure of PLC controller, generate the output signal of corresponding correct PLC controller intoRow replacement is corrected；If relay switch signal fault, generates corresponding relay switch signal and be replaced correction；If motorDriving signal failure then generates corresponding correctly motor drive signal and is replaced correction.
Fig. 5 is the circuit diagram of signal replacement module provided in an embodiment of the present invention, as shown in figure 5, with motor express letterFor number (53b), K1K2 relay is normally closed switch, and when needing to replace signal, single-chip microcontroller outputs signals to d1, makes K1, K2Must be electric, relay first disconnects 53b, is then connected to new replacement signal (24V), realizes signal replacement.The replacement electricity of other signalsRoad is similar.
On the basis of the above embodiments, Fig. 6 is a kind of acquisition module structural schematic diagram provided in an embodiment of the present invention, such asShown in Fig. 6, the acquisition module 1 is specifically included：
Analog acquisition unit 11, digital data acquisition unit 12 and signal processing unit 13；
The analog acquisition unit 11 is used to measure the analog signal of the driving mechanism, the digital data acquisition unit12 for measuring the digital signal of the driving mechanism, and the signal processing unit 13 is used for the analog signal to measurementAnd/or the digital signal carries out signal processing.
It is understood that the signal form of the correlation signal of driving mechanism can be mainly divided into analog signal form sum numberThe form of word signal, then correspondingly, acquisition module provided in an embodiment of the present invention 1 also include analog acquisition unit 11,Digital data acquisition unit 12 acquires analog signal and digital signal respectively, and analog signal is for example：Photosignal, motor three-phasePower supply, the output of motor Hall, digital signal is for example：Disconnecting switch signal, manual switch signal, then pass through signal processing unit 13Analog signal and/or the digital signal to acquisition carry out signal filtering and anti-interference process.
Specifically, analog acquisition unit 11 is mainly used for collection voltages signal, digital data acquisition unit 12 is mainly used forAcquire driving mechanism function knob on-off signal.And analog acquisition unit 11 can be by voltage transmitter by high voltage direct currentElectric signal is linearly converted to the manageable low-voltage direct electric signal of diagnostic module 2, and digital data acquisition unit 12 will be by that will simulateAfter voltage signal is measured by resistance decompression, capacitor filtering, high voltage analog signal is transformed into low and high level using optocoupler and is inputtedIt is used to diagnostic module 2 as digital signal.
Fig. 7 is acquisition module circuit diagram provided in an embodiment of the present invention, as shown in fig. 7, acquisition module can acquireKnob signal, PLC output signal, motor input signal, position sensor signal are " 0 " after conversion, " 1 " digital quantity is sent toDiagnostic module.
On the basis of the above embodiments, Fig. 8 is a kind of driving mechanism method for diagnosing faults provided in an embodiment of the present inventionFlow chart, as shown in figure 8, method includes：
801, the correlation signal of the driving mechanism of the acquisition module acquisition is obtained, the correlation signal includes severalA echo signal to be detected；
802, the correlation signal for detecting the driving mechanism, if any echo signal to be detected is unsatisfactory for preset functionLogical table parameter value is then diagnosed to be the corresponding fault type of corresponding function logical table.
By the content of above-described embodiment it is found that the embodiment of the invention provides a kind of driving mechanism trouble-shooters Lai realThe diagnosis of existing driving mechanism.Specific diagnostic method is shown in above-mentioned steps 801 and step 802.
In step 801, each correlation signal of driving mechanism can be obtained by acquisition module, wherein correlation signal packetInclude several echo signals to be detected detect set.Preferably, general correlation signal includes：Driving mechanismFunction knob signal, driving mechanism PLC output signal, driving mechanism motor input signal, driving mechanism position sensor signalDeng.
Further, in step 802, correlation signal is detected by preset function logic table, if wherein appointingParameter value in one echo signal to be detected and preset function logic table is unequal, then can judge diagnostics classes accordinglyType.
Table 1 is that a kind of driving mechanism function logic provided in an embodiment of the present invention indicates expectation.
1 driving mechanism of table works normally function logic table
It is understood that the embodiment of the present invention preferably uses single-chip microcontroller plate as diagnostic module, and accordingly by instituteCollection value when having signal to be adjusted to " 01 " digital quantity, and being worked normally by multiple driving mechanism, is determined as shown in Table 1Function logic table, the parameter value in table are the parameter value of function logic table.It should be noted that the function logic that table 1 providesTable is merely illustrative, is not especially limited to the content embodiment of the present invention that covers in specific parameter value and table.
It is so compared according to the correlation signal of the parameter value of function logic table and real-time measurement, that is, can determine driving machineWhether structure has some echo signal to be detected to be unsatisfactory for parameter value, so that it is determined that corresponding fault type out.
A kind of driving mechanism method for diagnosing faults provided in an embodiment of the present invention, passes through the association of automatic measurement driving mechanismSignal, and automatically match correlation signal in preset function logical table, so that whether diagnosis driving mechanism has occurred event automaticallyBarrier, reduces the labor intensity of technical staff and improves diagnosis efficiency.
On the basis of the above embodiments, the echo signal to be detected includes the master control power supply letter of the driving mechanismNumber；Correspondingly, the correlation signal of the detection driving mechanism, if any echo signal to be detected is unsatisfactory for default functionEnergy logical table parameter value, then be diagnosed to be the corresponding fault type of corresponding function logical table, including：
Whether master control power supply signal and the parameter value in the function logic table for detecting the driving mechanism are equal；
If the parameter value in the master control power supply signal of the driving mechanism and the function logic table differs, it is diagnosed to be instituteState the master control power failure that fault type is the driving mechanism.
It is understood that driving mechanism, which often will appear power supply, to be component power supply, i.e. master control power failure, needleTo such failure, the embodiment of the invention provides a kind of diagnostic methods.
Specifically, can refer to table 1, the embodiment of the present invention is according to the master control power supply signal and function of the driving mechanism of acquisitionThe parameter value that master control power supply signal is arranged in logical table is compared, if the master control power supply signal of driving mechanism is patrolled with the functionThe parameter value collected in table differs, then is diagnosed to be the master control power failure that the fault type is the driving mechanism.Such as：Table 1Middle master control power supply signal U1=1, if the master control power supply signal U1=0 of the driving mechanism of detection, then proving that master control power supply is sent outFailure is given birth to.
On the basis of the above embodiments, the echo signal to be detected includes the PLC power supply signal of the driving mechanism；Correspondingly, the correlation signal of the detection driving mechanism, if any echo signal to be detected is unsatisfactory for preset functionLogical table parameter value is then diagnosed to be the corresponding fault type of corresponding function logical table, including：
Whether PLC power supply signal and the parameter value in the function logic table for detecting the driving mechanism are equal；
If the parameter value in the PLC power supply signal of the driving mechanism and the function logic table differs, it is diagnosed to be instituteState the PLC power failure that fault type is the driving mechanism.
It is understood that there are also the power supplys that PLC is controlled for the driving mechanism power supply that includes, and the power supply is equally easy to appearFault condition, for such failure, the embodiment of the invention provides a kind of diagnostic methods.
Specifically, can refer to table 1, the embodiment of the present invention is patrolled according to the PLC power supply signal and function of the driving mechanism of acquisitionThe parameter value of the PLC power supply signal setting of driving mechanism is compared in volume table, if the PLC power supply signal of driving mechanism with it is describedParameter value in function logic table differs, then is diagnosed to be the PLC power failure that the fault type is the driving mechanism.ExampleSuch as：PLC power supply signal U2=1 in table 1, if the PLC power supply signal U2=0 of the driving mechanism of detection, then proving PLC power supplyFailure has occurred.
On the basis of the above embodiments, the echo signal to be detected include the driving mechanism PLC input signal,PLC output signal and motor speed driving signal；Correspondingly, the correlation signal of the detection driving mechanism, if anyThe echo signal to be detected is unsatisfactory for preset function logical table parameter value, then is diagnosed to be the corresponding failure of corresponding function logical tableType, including：
Obtain the current gear of the driving mechanism；
According to the PLC input signal and the current gear of the driving mechanism, the PLC output signal and institute are detectedWhether the parameter value stated in function logic table is equal, and detects in the motor speed driving signal and the function logic tableWhether parameter value is equal；
If the parameter value in the PLC output signal and the function logic table differs, it is diagnosed to be the fault typeFailure is exported for the PLC of the driving mechanism；
If the parameter value in the motor speed driving signal and the function logic table differs, it is diagnosed to be the failureType is the relay failure of the driving mechanism.
It is understood that driving mechanism, which often will appear PLC controller, to select inputing to for knob according to functionThe case where correct output signal and relay can not be closed or disconnect according to the output signal of PLC controller out, i.e.,PLC controller exports failure and relay failure, and for such failure, the embodiment of the invention provides a kind of diagnostic methods.
Specifically, can refer to table 1, according to the PLC input signal and the current gear of driving mechanism, need to illustrateIt is that driving mechanism is due to the difference of working condition, and gear also can be different, and common gear has respectively：" OFF " shutdown shelves,The gap " INT " shelves, " SLOW " shelves, " FAST " quick shelves at a slow speed.The PLC input signal of its generation of different gears, PLC output letterNumber and motor speed driving signal be all different.So the embodiment of the present invention needs first to carry out the current gear of driving mechanismIdentification.It is patrolled after confirmed the current gear of driving mechanism, then by PLC output signal and motor speed driving signal and functionThe parameter value collected in table compares, so that it is determined that fault type.
As shown in table 1：If PLC controller input signal is " 1000 ", gear is " OFF " shelves at this time.If PLC controllerOutput signal is " 0000 ", and motor speed driving signal is " 00 ", illustrates that driving mechanism is working properly in " OFF " shelves；IfPLC controller output signal is not " 0000 ", illustrates that PLC controller exports failure；If motor speed driving signal is not" 00 " illustrates that the relay of driving mechanism breaks down.
If PLC controller input signal is " 0100 ", gear is " INT " shelves at this time.If PLC controller output signal is" 1100 " are periodically switched to " 0000 ", and motor speed is that " 10 " are periodically switched to " 00 ", illustrate driving mechanism in " INT " shelvesWhen it is working properly；If PLC controller output signal is not that " 1100 " are periodically switched to " 0000 ", illustrate that PLC controller is defeatedIt is out of order；If PLC controller output is normal, motor speed driving signal is not that " 10 " are periodically switched to " 00 ", illustrates to driveThe relay of motivation structure breaks down.
If PLC controller input signal is " 0010 ", gear is " SLOW " shelves at this time.If PLC controller output signalFor " 1100 ", motor speed driving signal is " 10 ", illustrates that driving mechanism is working properly in " SLOW " shelves；If PLC is controlledDevice output signal is not " 1100 ", illustrates that PLC controller exports failure；If PLC controller output is normal, the driving of motor speedSignal is not " 10 ", illustrates that the relay of driving mechanism breaks down.
If PLC controller input signal is " 0001 ", gear is " FAST " shelves at this time.If PLC controller output signalFor " 1110 ", motor speed driving signal is " 01 ", illustrates that driving mechanism is working properly in " FAST " shelves；If controller is defeatedSignal is not " 1110 " out, illustrates that PLC controller exports failure；If PLC controller output is normal, motor speed driving signalIt is not " 01 " to illustrate that the relay of driving mechanism breaks down.
On the basis of the above embodiments, the echo signal to be detected includes the left sensor position of the driving mechanismConfidence number and right sensor position signal；Correspondingly, the correlation signal of the detection driving mechanism, if it is any it is described toDetection echo signal is unsatisfactory for preset function logical table parameter value, then is diagnosed to be the corresponding fault type of corresponding function logical table,Including：
Obtain a cycle acquisition time interval T of the left sensor position signalleft, and obtain the right side and passThe a cycle acquisition time interval T of sensor position signalright；
If TleftWith TrightIt is unequal, then it is diagnosed to be the asynchronous event of motor that the fault type is the driving mechanismBarrier.
It is understood that the difference of the left and right wiper arm cycle of operation exceeds the control model of PLC due to mechanical structure agingIt encloses, i.e. left and right driving mechanism operation is asynchronous, alternatively referred to as the asynchronous failure of motor, for such failure, the embodiment of the present inventionProvide a kind of diagnostic method.
Specifically, position sensor function logical table is as shown in table 2.
2 position sensor function logical table of table
As shown in table 2, the embodiment of the present invention respectively installs a position sensor in the right and left of driving mechanism, to detectWiper arm reaches the time on boundary, judges whether two wiper arms in left and right are same with the signal interval of two sensors in left and rightStep.Wherein, 1 corresponding wiper arm arrival boundary is represented, 0, which represents corresponding wiper arm, does not reach boundary.Acquire left-right positionThe signal of sensor calculates time interval T, T=tk-tk-1。tkAt the time of indicating that wiper arm reaches boundary, tk-1Indicate wiper armAt the time of preceding primary arrival boundary, if Tleft=Tright, then driving mechanism operating status in left and right is synchronous, otherwise, driving mechanismOperating status is asynchronous, i.e., driving mechanism produces the asynchronous failure of motor.
On the basis of the above embodiments, the method also includes：
Based on preset driving mechanism performance Index Calculation formula, the performance indicator of the driving mechanism is calculated；
Using the difference of the performance indicator of the driving mechanism and preset threshold as the remaining life of the driving mechanism.
By the content of above-described embodiment it is found that the embodiment of the invention provides a kind of driving mechanism method for diagnosing faults, energyEnough it is diagnosed to be whether driving mechanism breaks down.It is understood that each driving mechanism has the service life of oneself, it is remainingThe probability that the lower driving mechanism of life breaks down is higher, and emphasis is needed to detect.For said circumstances, the present invention is implementedExample provides a kind of life prediction mode of driving mechanism, carries out reasonable prediction to the remaining life of driving mechanism.
Specifically, the embodiment of the invention provides a kind of driving mechanism performance Index Calculation formulas：
Wherein, xi1、xi2The parameter that can reflect driving mechanism operating status is represented, is measurable variable in this i=4, according toElectric moter voltage, motor speed, output electric current, scraping arm swing period determine.xi1Left side scraping arm and corresponding parameter of actuating mechanism are represented,xi2Right side scraping arm and corresponding parameter of actuating mechanism are represented,Represent normal condition lower drive mechanism operating parameter, αiRepresent stateParameters weighting, J are driving mechanism performance indicator.
Become it is understood that performance indicator J provided in an embodiment of the present invention reflects the variation of driving mechanism operating statusGesture is realized fault detection by Monitoring Performance index, when driving mechanism performance indicator is approached or is prescribed a time limit more than control, is illustrated at this timeThe operating status of driving mechanism is deteriorated or has already appeared failure, needs to carry out troubleshooting in time.Wherein, the control limit isPreset threshold described in the embodiment of the present invention is that rule of thumb or largely statistics is arranged.
Further, the residue that can calculate driving mechanism is made the difference by the performance indicator J and preset threshold that will measureService life.
Method provided in an embodiment of the present invention is capable of the service life of accurate measurements driving mechanism, allows the operator toIt is managed accordingly according to the remaining life of driving mechanism and regulating measures.
Through the above description of the embodiments, those skilled in the art can be understood that each embodiment canIt realizes by means of software and necessary general hardware platform, naturally it is also possible to pass through hardware.Based on this understanding, onStating technical solution, substantially the part that contributes to existing technology can be embodied in the form of software products in other words, shouldComputer software product may be stored in a computer readable storage medium, such as ROM/RAM, magnetic disk, CD, including several fingersIt enables and using so that a computer equipment (can be personal computer, server or the network equipment etc.) executes each implementationMethod described in certain parts of example or embodiment.
Finally it should be noted that：The above embodiments are merely illustrative of the technical solutions of the present invention, rather than its limitations；AlthoughPresent invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that：It still may be usedTo modify the technical solutions described in the foregoing embodiments or equivalent replacement of some of the technical features；And these are modified or replaceed, technical solution of various embodiments of the present invention that it does not separate the essence of the corresponding technical solution spirit andRange.